Flat top container fabricating machine



May 15, 1956 c. z. MONROE ET AL FLAT T01D CONTAINER FABRICATING MACHINE:

17 Sheets-Sheet l Filed Nov. lO, 1952 May S, i955 c. z. MONROE ET AL 2,745,323

FLAT TOP CONTAINER FABRICATING MACHINE Filed Nov. lO, 1952 17 Sheets-Sheet 2 Inventors C hat' les monroe James E Eagp EW@ a,

M L Wife, 1155s May 15, 1956 c. z'. MONROE ET AL 2,745,323

FLAT TOP CONTAINER FABRCATING MACHINE Filed Nov. l0, 1952 17 Sheets-Sheet 3 ff L); U72' Inventors Charles j. monroe James F Bag May 15, 1956 c. z. MONROE ET AL 2,745,323

FLAT TOP CNTINER FABRICATING MACHINE Filed Nov. lOI 1952 17 Sheets-Sheet 4 Inventors C Charles j. monroe James E Eng) May 15, 1956 c. z. MONROE ET AL 2,745,323

FLAT TOP CONTAINER FABRICATING MACHINE Filed Nov. 1o, 1952 17 sheets-sheet 5 Inventors Charles j. monroe James F.' Ea-p 25:62, /Z';.., Wig/gg May l5, 1956 c. z. MONROE ET AL 2,745,323

FLAT TOP CONTAINER FABRICATING MACHINE 17 Sheets-Sheet 6 Filed Nov. 10, 1952 Inventors Chorles.monroe James F.' Eug:

c. z. MONROE ET AL 2,745,323

FLAT TOP CONTAINER FABRTCATING MACHINE 17 Sheets-Sheet 7 Inventors Charles j. monroe James F.' EarJa 3 @EA 1 i May l5, 1956 Filed Nov. 10, 1952 May 15, 1956 c. Z. MONROE ET AL 2,745,323

FLAT TOP CONTAINER FABRICATING MACHINE Filed Nov. lO, 1952 17 Sheets-Sheet 8 Inventors Charles .monroe James Eug) wEHS- May 15, 195.6 c. z. MONROE ET AL 2,745,323

FLAT TOP CONTAINER FABRICATING MACHINE Filed Nov. l0, 1952 17 Sheets-Sheet 9 98 Y Inventors 95 96 Charles j. monroe May 15, 1956 C. Z. MONROE ET AL FLAT TOP CONTAINER FABRICATING MACHINE Filed Nov. l0, 1952 17 Sheets-Sheet 10 Inventors Charles j. monroe James F. Earp c. z. MONROE ET AL 2,745,323

17 Sheets-Sheet ll May 15, 1956 FLAT TOP CONTAINER FABRICATING MACHINE Filed Nov. l0, 1952 May 15, 1956 c. z. MONROE ET AL 2,745,323

FLAT TOP CONTAINER TABRTCATING MACHINE Filed NOV. l0, 1952 17 Sheets-Sheet 12 25s ci@ Z2, Z l 58 a .Eur 135,2 '/gdjmes *gt/ May 15, 1956 c. z. MONROE ET AL 2,745,323

FLAT ToP CONTAINER FABRICATTNG MACHINE 17 Sheets-Sheet l5 Filed Nov. lO, 1952 s. e wf rmmJ May 15, 1956 c. z. MONROE ET AL 2,745,323

FLAT TOP CONTAINER FABRICATING MACHINE 17 Sheets-Sheet 14 Filed NOV. lO, 1952 Inventors Charles/9. mon roe James E Eap 'm ag, www# S.

May l5, 1956 c. z. MONROE ET AL 2,745,323

FLAT TOP CONTAINER FABRICATING MACHINE Filed Nov. 10, 1952 17 Sheets-Sheet l5 r 2 i Inventors 26' Charles monroe 3l 38 00 Ej: James F Earlp May 15, 1956 c. z. MONROE ET AL 2,745,323

FLAT TOP CONTAINER FABRICATING MACHINE Filed Nov. 10, 1952 17 Sheets-Sheet 16 Inventors Char-les j. monroe James E Eug) May 15, 1956 c. z. MONROE ETAL 2,745,323

FLAT TOP CONTAINER F'ABRICATING MACHINE Filed Nov. lO, 1952 17 Sheets-Sheet 17 Inventors.A Charles j., monroe James E' Eug:

mi algys.

United States Patent FLAT froP coNTAINER AFABRICA'HNG :MACHINE Charles Z. Monroe and James F. Earp, Detroit, rMich., assignors to Ex-Ce'lLO Corporation, Detroit, fMich., a lcorporation of Michigan Application November 10, 1952, Serial No. 319,684

18 Claims. (Cl. S13-36.8)

The present invention relates .to container fabricating machines and, more specifically, to a `machine for making disposable cartons of paperboard or other bendable sheet material.

The invention finds particular, -but not exclusive, utility in a machine for forming dat-topped cartons such as the ones disclosed in copending application Serial No. 135,430 tiled December28, 1949, by .Charles H. Dixon, and also in Patent No. 2,581,237 issued January l, 1952, upon the application of Roger H. -Caslen Such cartons are self-sustaining in shape and, whencoated or impregnated to render them impervious, are particularly well suited for the distribution of milk :and other comestibles.

The general aim of the .present invention is -to :provide a machine of the character set ,forth .and .having novel top Vpreforming and top closing units, such units being capable of receiving an erected carton body having a closed bottom and an open top, manipulating vthe upper end of the carton body to .complete the Vforming of its top closure, and ultimately presenting the completed carton to a discharge conveyor.

Another Objectis to provide a high-speed, .continuous motion machine of the type just mentioned, performing its operations upon a procession of 1blanks moving through the machine at a rapid but substantially y.constant rate.

A further object is to provide a machine of the character set vforth and which will be easy to clean .and .maintain, fully conforming to the .rigorous sanitary requirements that Vmust be met Yfor dairy equipment and similar applications.

Other objects and advantages will become apparent as the following detailed description proceeds, taken together with the accompanying drawings, wherein:

Figure l is a side elevation of .an illustrative carton fabricating machine embodying the Apresent invention.

Fig. 2 is a plan View of the illustrative machine of Figure 1.

Fig. 3 is an enlarged, lfragmentary perspective view of the upper ,portion of a carton body and showing 'the top closure parts prior to entry of .the body .into lthe top preformer unit.

Figs. 4, 5 and 6 are stop-motion views showin'gse'quentially Vthe steps in outfolding of `the front and rear 'top flange panels of the carton.

Fig. 7 is an enlarged, fragmentary perspective v'iew of .the upper portion of the carton body ,as Aits front and rear top anges are outfolded vand confined by .the stationary hold `down cams.

Figs. 8 and 9 are enlarged, fragmentary vertical sectional views taken through the preformer unit in the planes of the lines 8-8 and '16-16, respectively.

Fig. 10 is an enlarged, fragmentary perspective view of the upper portion .of the carton body .and showing the adhesive coating on the .inside major :top 'ap .and the -outfolded top hange.

lFig. L1 1 is an enlarged, fragmentary horizontal sec- ICC 2 tional view taken -al'ong the top flange hinge line and in "the .plane of 'the line 11-11 in Fig. 5.

Fig. 1.2 is an enlarged, fragmentary perspective view showing the hold down and squeezer cams of the preformer unit.

Fig. 13 is an enlarged plan view of the top preformer unit with one cover cut away to permit illustration of the inside details, such view being `taken 'from the plane of 'the line 13`13-in Fig. l.

Fig. 14 is an enlarged, fragmentary elevation of the top Vpreform'er unit, 'taken in the plane of the line 14-14 in Fig. T2.

Fig. 'l5 is an enlarged, .fragmentary vertical lsectional View through the top preformer unit taken in the plane 'of the line l5- '15 in Fig. 14.

Fig. 1/6 is `an enlarged, vertical sectional view through the top preforrner .unit and taken in the plane of the .line 'I6-1651i Fig. 13.

Fig. 17 is :an enlarged, fragmentary perspective View 'of "the lupperiportion of the carton shortly after leaving the top preformer unit.

Figs. 118 and r1.9 are detail views showing certain steps inithe l'clownfolding ofthe outside major top flap andthe gripping tab projection thereof.

Figs 20 and 21 are enlarged Aplan views showing the terminal rsheave disk and fragmentary portions of ythe ytop Vpre'former lunit 'and the top closing turret ladjacent :th-creto.

Fig. 22 is a vertical sectional view through =the top closing turret, taken in the plane ofthe line 22-22 in Fig. 2.

Fig. .2.3 is 1an enlarged, fragmentary elevation detailing 4certain vmechanisms housed Within the top closing turret -iof the machine.

Fig. .-24 .is an enlarged, fragmentary horizontal sectional Aview Athrough kthe top .closing turret taken in the :plane 'oftheIline124-24 in Fig. l.

Fig. 25'isfanen'larged, .fragmentary horizontal sectional view through the top closure head 'taken in the plane of the :line Y2S-4.25 rin Fig. 23.

Fig. v26 '.is :an enlarged, 'fragmentary vertical sectional view "through ithe vtop .closure head shown in the lower portion of Fig. .23.

Fig. 2.27 .is ahorizontal sectional view corresponding to .'Fig.l25 but showing the jaws in open rather than 'closed position.

Fig. 28 is an enlarged, fragmentary elevation detailing certain manipulating devices incorporated into the top closure head 'of Fig. 23.

Fig. A29 is an enlarged, :fragmentary vertical sectional View through the top closure head taken in the plane ofthe line 29--29 of Fig. v27.

Fig. l3() is an enlarged, fragmentary perspective .View detailing one of the heated pressure pads carried bythe top closing turret vand certain manipulating elements associated therewith.

Fig. 311 is an enlarged, vertical sectional View through one of Vthe'pressure pads carried by the top closing turret. Fig. 32 is a'frag'mentary vertical sectional View taken in the plane of the line A32--32 in Fig. 31.

vinvention to the specic form disclosed, but on the contrary, .the intention is to cover all modifications, alternative constructions, and equivalents, falling within `the spirit and scope of the invention as expressed in the claims.

appended General machine organization Referring more speciiically to Figs. l and 2, the invention is there exemplified in an illustrative container fabricating machine 50 which happens to be of the continuous motion type. vBy this is meant that the cartons being formed by the machine are moved through the latter in a continuous procession at a substantially constant rate, the Vforming operations lbeing carried on while the carton blanks and bodies are in motion.

The machine 50 comprises a base 51 fashioned as a Y closed housing and having legs 52 which support the base a sucient distance yabove the floor to permit thorough cleaningV and inspection beneath the machine. kMounted on the base 51 are a blank feeder mechanism 54, body f forming unit S5, atop preformer unit 56, a top closing unit 58 and a conveyor 59. The blank feeder mechanism 54, which may be similar to the one disclosed in copendv ing application Serial No. 50,147 filed September 20, 1948 (now Patent 2,636,733, issued Apr. 28, 1953), by Arthur '1. Lewis, is adapted to hold a stack of single ply, horizontally disposed blanks and to feed them one by one up an arcuate guideway, presenting each blank in a verticalposi- 'tionl to the body forming unit 55. The latter is constructed and arranged to erect the blank into a tubular carton body and to complete the bottom closure of the carton body, eventually delivering the latter to the top preformer unit 56. The preformer unit 56 is arranged to break the top closure elements of the carton body in the 1 proper manner to facilitate the subsequent steps in the formation of the top closure. An appropriate conveying Vmeans moves each carton body through the preformer unit 56 and thereupon delivers it to the top closing unit 58. This unit performs all the steps necessary to complete the top closure except for securing the lling flap in sealed position. The substantially completed cartons are then Ydelivered by the top closing unit 5S to the discharge con- Top closure parts When delivered to the top preformer unit 56, each carton C comprises a tubular rectangular body with a closed bottom and an open top. However, the parts which ultimately define Vthe top closure of the carton are all pre- Y formed and selected areas on them are coated with thermoplastic adhesive. Since these parts are all in the upper portion of the carton body, only such portion need be described in detail herein.

Referring in particular to Figs. 3, 7 and 10, it will be perceived that the top closure parts of the carton C are situated above a common score line 60, which, incidentally, constitutes the top boundary of the carton body side panels. Corner score lines 61, 62, 64 and k65 of the carton body continue up into the top closure and divide the same into major areas coplanar with the respective side panels. A second common Score line 66 cuts through the major panel areas of the top closure and defines, between itself and the score line 60, opposed front and rear roof panels 63, 69, as well as opposed side roof panels 70, 71.Y Front roof panel 68 is flanked by a pair of small gusset panels 72, 74, connected thereto along score lines 75, 76, respectively. larly flanked by gusset panels 78, 79 connected-.thereto along score lines 80, 31, respectively.

Rear roof panel 69 is simi' Hinged to each of the roof panels 68, 69, 70, 71 along the common score line 66, is a relatively narrow top ange Vcomprising ange'panels 68A, 69A, 70A, 71A.

lThe ange panels 68A, 69A are anked respectively by fractional panel areas 72A, 74A, 78A and 79A. The panel areas 72A, 74A are connected to the flange panel 68A along score lines 75A, 76A, respectively. By the same token, the fractional panel areas 78A, 79A are connected to the ange panel 69A along score lines 80A, 81A, respectively.

A11 inner top flap 82 of generally rectangular shape is hingedly connected to the flange panel A along a score line 84.- The ap 82 has a relatively large aperture 85 which serves both as a filling opening and a dispensing opening. The flap 82 also includes a projecting portion 86 adapted to coact with other members of the top closure in initially holding down the lift tab,

Hingedly connected to the flange panel 71A along a score line 88 is outer top flap 89. The latter includes a lift lab 90 terminating in a projecting portion comprising the tab areas 91, 92 and 94 and transverse score lines 95, 96. The top flap 89 also includes a filling ap 98 connected therewith along a transverse score line 99 and separated from the ange panel 71A by severance line 100.

As indicated by the stipplcd areas shown in Figs. 3, 7 and l0, selected areas of the top closure parts are precoated with a suitable thermoplastic adhesive 101. In this instance, the adhesive 101 is applied t0 those areas of the top ange which initially face the inside of the carton. lt is also applied to the inside face of the inner top ap 82 so as to surround the filling and dispensing opening 85. A limited amount of adhesive is also applied to the inside face of the projection 86 on the inner top ap 82. The outer top flap 89 has a band of adhesive extending around its lateral and marginal edge portions. ln addition, certain small areas of the lift tab 90 and the tab panel 91 also have adhesive precoated thereon.

Top preformer unit As shown in Figs. l, 2, 13, 14 and 16, the top preformer unit 56 comprises a hollow upright standard 104, together with a surrounding preformer conveyor 105 and a carton supporting table 106.

The conveyor 105 'comprises a series of open-sided buckets 108 constrained to move in an orbital path about the standard 104. Conveyor buckets 103 are adapted to receive from the body forming unit 55 a procession of open-topped carton bodies, each in the condition illustrated in Fig. 3, and to traverse the carton bodies along the table 106 for manipulation by the top preformer unit 56,

Each conveyor bucket 108 (Fig. 16) comprises an upstanding side panel having one or more relatively long trailing fingers 109 and one or more relatively short leading ngers 110, being connected by means of an integral olset bracket 111 to a double roller chain 112. In'the present instance, the chain 112 is conlned between laterally spaced guides 114 secured to the machine base as by blocks 115.V To insure retention in the buckets 108 as the cartons are traversed through the top preformer unit 56, the latter may also include one or more guide rails 116 disposed in closely spaced relation with the course of the buckets 10S.

At its upper end, theV standard 104 terminates in an elongated gear box 118, closed by a cover 119. T he gear box 118 supports a plurality of top closure manipulating elements disposed in overlying relation with the carton supporting table 106 and housed Within a removable protective cover 120.

The iirst manipulation to take place in the top preformer unit is the infolding of front and rear roof panels 68, 69 and the outfolding of'their associated flange panels 68A, 69A. In furtherance of this objective, the unit 56 is provided with a pair of rotary breakers 121, 122 of substantially identical form but opposite hand (Fig. 13). 'I'he annees unit 121 .has a pair of diametrically opposed retarding ngers 124 each adapted to serve as a receding -abutment and to contact the leading or front roof panel `68 of the carton just beneath the score line 66 (Fig. 4). The unit 122 has a pair of diametrically opposed accelerating fingers 125 each adapted to serve as an overtaking abutment and to vcontact the trailing or rear roof panel 69 ljust below 'the score line 66 (Figs 5 and 11). During the interval of lcontact between a pair of these fingers and a given carton, the relationship of the parts is such that the finger 124 will have a linear velocity component along the path of the carton somewhat less than the carton velocity, while the linger 125 will have a similar llinear velocity component somewhat greater than the 'velocity ofthe carton. Such action of course results in infolding the front and rear roof panels 68, 69, and also in infolding their neighboring triangular gusset panels 72, 74, 78, 79.

Outfolding -of the leading ange panels 68A (Figs. 4, 5 and 7) at this time is accomplished -by forcing the same under a hold down cam 126 fixed in overlying relation with the carton path and by the use of a notched folder wheel 128 driven in a counterclockwise direction as viewed in Figs. 4 and 5. The'wheel 128 is formed with a'peripheral groove 129 adapted `to straddle the end of the hold down cam 126. Each of the circular rigs flanking the groove 129 of the wheel 128 has a pair of diametrically opposed, rsecantial notches terminating Vin alined pairs of radial abutments 130. As shown in Fig. 4, the abutments 130 accost the ange panel 68A and outfold it so that its free upper edge becomes confined between the upper face of the retarding finger 124 and the lower fa'ce of 'the hold -down cam 126.

Outfoldin'g Aof -.the trailing 'flange panel 69A is accomplis'hed by the use of a hold down cam 131 also mounted in overlying relation with the carton path, the panel VV69A being conned between the upper face of accelerating linger 125 and the lower face of the hold d'own cam 131.

In order to avoid improper rearward folding of the leading ange panel 68A against the bottom of the hold `down cam 131, the latter is spaced Ya sucient distance above the table 106 to give the flange panel '68A lproper clearance. For the same purpose, ithe yhold down cam 131 is spaced from the Vend/of 'the hold down cam 126 and the table is provided with a lifter 'cam 132, the latter having an inclining ramp 134 and a declining ramp 135. The location of the lifter cam 132 is such 'that fthe carton C will tilt rearwardly as the 'flange panel 68A clears the 'end portion of the hold down cam 131, the associatedconveyor bucket 108 being suicient'ly oversize to permit limited tilting of the carton. Further movement of the carton onto the lifter cam 132 .restores the carton to vertical position and also increases the pressure which the hold down cam 131 brings to bear against the trailing flange panel 69A. At this point, the `notched wheel 128, coacting with the retarding finger 124, folds the leading ange panel '68A downwardly .and outwardly in ythe manner'already described. The carton C continues its linear advance along the table 106 and llifter cam 132, the outer periphery of the notched wheel 128 serving to hold down the trailing 'flange panel 69A until 'the latter moves vinto underlying relation with the hold down cam 126. As the carton C travels 'along the declining ramp '135 of the lifter cam 132, the undersurface of 'the hold 4down cam 126 declines proportionally so as to 'maintain an appropriate degree of downward deflection on the outfolded flange panels 68A, 69A (Figs. 5 and 6).

For the purpose of infolding the side roof panels 70, 71 and outfolding their respective flange panels 70A, 71A as the carton C continues through the preformer, the hold down cam 126 has a progressively Widening portion 138 and its underside becomes lower, exerting an increasing downward pressure over a widening area of the flange panels 68A, 69A. A pair of squeeze cams 139is mounted in straddling relation with the widening portion 138 of the hold down cam 126 (Figs. 8, 9, 12 and 13). 'I'he squeeze cams 139 have inside longitudinal faces 140 which, when viewed in plan as in Fig. 13, converge toward the hold down cam 126 and ultimately cross under diverging lateral edges 141 of the cam 126, straightening out in underlying relation with the marginal edge portions of the widest part of the cam 126. The converging edges 140 of squeeze cams 139 also diverge downwardly, each at an angle complementary to the desired ultimate inclination of its associated one of the side roof panels 70, 71 (Figs. 8, 9 and 12).

As the carton C moves into contact with the end portions of the squeeze cams 139, the lateral edges of the cams 139 exert opposed inward thrusts on the side roof panels 70, 71 at or immediately below the score line 66. As the carton C continues its traverse through the preformer, these thrusts, coupled with the downward thrust produced by the widening portion 138 of the hold down cam, infold the side roof panels 70, 71 and at the same time outfold their associated top flange panels 70A, 71A, as shown in Fig. 9. The major top flaps 82, S9 remain upright and simply fold through an angle of about 90 about the respective score lines S4, 88 connecting them with their associated top flange panels. Such action also results in folding the Vfractional panel areas 72, 72A and 79, 79A against the inside faces of the side roof panel 70 andthe top flange panel 70A, the fractional panels 72A, 79A simply outfolding with the top flange panel 70A. Similarly, the fractional panel areas 74, 74A and 78, 78A simply fold against the inside faces of the side roof panels 71 and its associated top flange panel 71A, the areas 74A, 78A outfolding with the top flange panel 71A. Upon completion vof the foregoing manipulations, the roof panels and the top flange of the carton C are in the conditionillustrated in Figs. 9 and 10.

In order to insure full breaking of the top closure parts about the proper score lines during the preforming operations just described, and also to preclude inward deformation of one or more of the carton side panels, provision is made for subjecting the inside of the carton C to a blast of compressed air during the severest part of the preforming operation. In furtherance of this objective, the hold down cam 126 is provided with an air line 142 terminating in 'a `discharge aperture in the widening portion 138 of the cam 126. The line 142 is connected with an intermittently operated air valve (not shown) which may be opened and closed in timed relation with the motion ofthe preformer conveyor 195. Since the portion 138 of the hold down cam at that particular point covers the entire top openingof the carton C, it will be appreciated that the air blast from lthe line 142 is sutllcient to place the entire carton under sufllcient internal pressure to offset deformation during preforming of the top closure.

After roof panels r68, 69, 70 and 71 have been infolded and the -ilange panels 68A, 69A, 743A, 71A have been outfolded, the carton is traversed further until its upstanding inside top flap 82 is accosted by a stationary turn clown cam 145 (Figs. 13 and 14). The latter has an abruptly tapered edge 146 which exerts a progressively increasing force on .the -top flap 82 tending to fold the same downwardly about the score line 84 and against the adhesive coated faces of the outfolded top flange panels 68A, 69A, 70A and 71A. Fixed to the Wider end of the cam 145 is a hold down shoe 148 which also has a tapered lateral edge v149. The shoe 148 extends downwardly from the cam 145 and becomes substantially coplanar with the adjacent end of the hold down cam 126. It will be appreciated, therefore, that the edge 149 of the shoe 148 completes the downfolding of the inside top ap 32 and `that the bottom face of the shoe simply maintains a downward pressure on the flap 82 and the underlying top flange. This pressure continues even after the carton C has left the preformer unit 56.

Provision is made in the Vpreformer unit 56 for main- 75 taining the outside ilap 89 in an upstanding position clear 

